Abrasive Types & Shapes: Consider These Two Things When Choosing Flap Disc

Over the last few years, flap discs have become one of the fastest growing abrasives categories in metal fabrication. From a product performance perspective, they are ideal for removing fast stock and providing blending, grinding, and finishing at a lower cost. They are also good for cooler cutting with less gouging and burning.

With all the benefits afforded by flap discs, it is vital to know how to choose the right one.  Here are the five pointers you need to consider when choosing flap disks for metal. 

Shapes

No doubt, flap disks are used on angle grinders to work at a shallow angle or even flat of the metal surface. The angle at which the disc is presented to the workpiece lets you know how aggressive the grinding action is required. To meet this, usually three types of flap disks are made: conical shaped discs, flat faced discs and flat faced discs with a flexible edge.

•  Flat Construction: Flat faced discs are generally required when it comes to finish or control more controlled grinding applications and a lower grinding pressure is required to the disc.

•  Conical Discs: These dicks are also called bevel edged flap discs. They are good for high aggression applications. They are among the most commonly preferred shape of flat disc. Conical Discs allow you to have a flat grinding face in direct contact with the metal fabrication.

• Plastic Fibre Backing on the Flap Disc: Earlier flap discs were made with aluminium backing plate. Today, they come with the glass fibre backing. A semi rigid backing allows for high aggression grinding whilst allowing some control. If you need greater control or reduced vibration, then it is the best choice.

Abrasive Types

Type of abrasive grain you choose is also matters a lot. Generally, two popular types are Ceramic alumina and Zircon alumina.

•  Ceramic alumina:  This is a great cut under high pressure grinding applications.  Ceramic grain grinding on steel, stainless steel and aluminium and alloy metals such as waspalloy are good in 40 and 60 grit forms. 

•  Zircon alumina:  They are a high quality blend of zirconia and aluminum oxide grain. They are used for the accurate cut vs cost ratio.  They good for steel grinding applications. 

To sum up, decide the shapes and types of abrasive before choosing any flap discs for metal.